Electrical connector with terminal array

CROSS REFERENCE TO RELATED APPLICATIONS

0001This application is a continuation of application Ser. No. 14/075,737, filed Nov. 8, 2013, now U.S. Pat. No. 9,461,409, which is a continuation of application Ser. No. 13/010,533, filed Jan. 20, 2011, now U.S. Pat. No. 8,591,248, which applications are incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

0002The subject matter described herein relates to an electrical connector and, more particularly, to an electrical connector having a terminal array.

BACKGROUND OF THE INVENTION

0003Electrical connectors are commonly used to couple a cable to a corresponding jack, cable, electrical device or the like. The electrical connector includes wire terminals positioned at a wire end of the connector. The wire terminals are configured to terminate twisted pairs of the cable and are generally housed in a load bar that is positioned within the connector. Specifically, each wire of a twisted pair is separated and joined to a terminal in the load bar. Contacts are coupled to the load bar at a mating end of the connector. The load bar carries electrical signals, for example, power and/or data signals, from the cable to the contacts. The contacts are configured to mate with corresponding contacts of the jack, cable, electrical device or the like. Accordingly, the connector carries the electrical signals from the cable to the corresponding jack, cable, electrical device or the like.

0004However, conventional electrical connectors are not without their disadvantages. In some electrical connectors wire terminals are positioned in close proximity to one another. Accordingly, electromagnetic crosstalk may be experienced between the wire terminals. Specifically, the wire terminals may experience crosstalk between differential pairs of the cable. Excessive crosstalk may impair the performance of the connector. For example, the crosstalk may reduce a speed at which the connector is capable of carrying the electrical signals. The crosstalk may also interfere with the electrical signals, thereby rendering the connector inoperable.

0005Additionally, conventional connectors typically include limited space for coupling wires thereto. For example, each wire of a cable must be joined to the connector within the confines of the load bar. The load bar may not be capable of accommodating all sizes of wire. As such, the connector is limited to use with cables having wire that is capable of joining to the load bar.

0006A need remains for an electrical connector that controls crosstalk between the differential pairs of a cable. Another need remains for an electrical connector that is capable of accommodating different size wires.

SUMMARY OF THE INVENTION

0007In one embodiment, an electrical connector is provided. The connector includes a housing having a wire end and a mating end. The housing has a bottom extending between the wire end and the mating end. A terminal array extends between the wire end and the mating end of the housing. The terminal array has second terminals and first terminals. The second terminals and the first terminals have a wire end and a mating end. The mating ends of the second terminals are aligned with the mating ends of the first terminals. The wire ends of the second terminals are positioned closer to the wire end of the housing than the wire ends of the first terminals. A wire contact is positioned at the wire end of each of the second terminals and the first terminals. The wire contact of each first terminal is positioned a distance from the bottom of the housing. The wire contact of each second terminal is positioned a distance from the bottom of the housing that is different than the distance of the wire contacts of the first terminals. Mating contacts are positioned at the mating end of the second terminals and the first terminals. The mating contacts of the second terminals are aligned and alternate with the mating contacts of the first terminals.

0008In another embodiment, a terminal array for an electrical connector is provided. The terminal array has a length and a height. The terminal array has second terminals and first terminals. Each of the second terminals and the first terminals has a wire contact and a mating contact. The wire contact of each second terminal is offset from wire contact of each first terminal along the length of the terminal array. The wire contact of each second terminal is offset from the wire contact of each first terminal along the height of the terminal array.

0009In another embodiment, an electrical connector is provided. The connector includes a housing having a wire end and a mating end. A bottom extends between the wire end and the mating end. A terminal array extends between the wire end and the mating end of the housing. The terminal array has second terminals and first terminals. The second terminals and the first terminals have a wire end and a mating end. The mating ends of the second terminals are aligned with the mating ends of the first terminals. The wire ends of the second terminals are positioned closer to the wire end of the housing than the wire ends of the first terminals. A wire contact is positioned at the wire end of each of the second terminals and the first terminals. The wire contact of each first terminal is stepped up a distance from the wire contact of each second terminal with respect to the bottom of the housing. Mating contacts are positioned at the mating end of the second terminals and the first terminals. The mating contacts of the second terminals are aligned and alternate with the mating contacts of the first terminals.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is a top perspective view of an electrical connector formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 2</figref> is a top perspective view of the electrical connector shown in <figref idref="DRAWINGS">FIG. 1</figref> and having the shield removed.

<figref idref="DRAWINGS">FIG. 3</figref> a top perspective view of the electrical connector shown in <figref idref="DRAWINGS">FIG. 2</figref> and having the retention housing removed.

<figref idref="DRAWINGS">FIG. 4</figref> is an exploded view of the connector shown in <figref idref="DRAWINGS">FIG. 2</figref>.

<figref idref="DRAWINGS">FIG. 5</figref> is a top perspective view of a connector housing formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 6</figref> is a side perspective view of a first terminal formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 7</figref> is a side perspective view of a second terminal formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 8</figref> is a side view of a terminal array formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 9</figref> is an exploded view of an electrical connector formed in accordance with another embodiment.

<figref idref="DRAWINGS">FIG. 10</figref> is a top perspective view of an electrical assembly formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 11</figref> is a side perspective view of a first terminal formed in accordance with another embodiment.

<figref idref="DRAWINGS">FIG. 12</figref> is a side perspective view of a second terminal formed in accordance with another embodiment.

<figref idref="DRAWINGS">FIG. 13</figref> is a side perspective view of a front mating contact formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 14</figref> is a side perspective view of a rear mating contact formed in accordance with an embodiment.

<figref idref="DRAWINGS">FIG. 15</figref> is a top perspective view of a terminal array formed in accordance with another embodiment.

DETAILED DESCRIPTION OF THE DRAWINGS

0025The foregoing summary, as well as the following detailed description of certain embodiments will be better understood when read in conjunction with the appended drawings. As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural of said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property.

0026<figref idref="DRAWINGS">FIG. 1</figref> illustrates an electrical connector <b>100</b> formed in accordance with an embodiment. In an exemplary embodiment, the electrical connector is a RJ-45 plug. However, the embodiments described herein may be used with any suitable connector, receptacle or plug. The electrical connector <b>100</b> includes a wire end <b>102</b> and a mating end <b>104</b>. The wire end <b>102</b> is configured to be joined to a cable <b>106</b>. The cable <b>106</b> is inserted into the wire end <b>102</b> of the connector <b>100</b> in a loading direction <b>107</b>. The cable <b>106</b> includes a conductor <b>108</b> having wires <b>110</b> arranged in twisted pairs. In one embodiment, the wires <b>110</b> are arranged in differential pairs which enable signal transmission via signals on separate wires that are approximately 180 degrees out of phase with each other. The wires <b>110</b> of the cable <b>106</b> are configured to be electrically coupled to the connector <b>100</b>. The mating end <b>104</b> of the connector <b>100</b> is configured to join a corresponding connector (not shown).

0027The connector <b>100</b> includes a housing <b>112</b> and a shield <b>114</b>. The housing <b>112</b> may have a size similar to that of a Cat.-6 housing. Cat.-6 cable is the standard for Gigabit Ethernet and other network protocols that are backward compatible with the Category 5/5e and Category 3 cable standards. Cat.-6 features more stringent specifications for crosstalk and system noise. The Cat.-6 cable standard provides performance of up to 250 MHz and is suitable for 10BASE-T, 100BASE-TX (Fast Ethernet), 1000BASE-T/1000BASE-TX (Gigabit Ethernet) and 10GBASE-T (10-Gigabit Ethernet). Cat.-6 cable has a reduced maximum length when used for 10GBASE-T, is characterized to 500 MHz and has improved alien crosstalk characteristics, allowing 10GBASE-T to be run for the same distance as previous protocols.

0028In an exemplary embodiment, the housing <b>112</b> is formed from polycarbonate. Alternatively, the housing <b>112</b> may be formed from any suitable non-conductive material. The housing <b>112</b> has a mating end <b>116</b> and a wire end <b>118</b>. The shield <b>114</b> is joined to the wire end <b>118</b> of the housing <b>112</b>. The shield <b>114</b> includes a housing portion <b>120</b> and a cable portion <b>122</b>. The housing portion <b>120</b> is joined to the wire end <b>118</b> of the housing <b>112</b>. The cable portion <b>122</b> extends from the housing portion <b>120</b>. The cable portion <b>122</b> is joined to the cable <b>106</b>. The shield <b>114</b> protects the connector <b>100</b> from electro-magnetic interference.

0029The housing <b>112</b> includes a top <b>124</b> and a bottom <b>126</b>. The top <b>124</b> of the housing <b>112</b> includes a plurality of mating contacts <b>128</b>. The mating contacts <b>128</b> are configured to electrically couple to contacts positioned on the corresponding connector. The mating contacts <b>128</b> create an electrical connection between the connector <b>100</b> and the corresponding connector. The mating contacts <b>128</b> may be formed from phos-bronze. The mating contacts <b>128</b> may include a gold plated surface. Alternatively, the mating contacts <b>128</b> may be formed from any suitable conductive material and/or have any suitable conductive plating.

0030The bottom <b>126</b> of the connector <b>100</b> includes a latch <b>130</b>. The latch <b>130</b> is configured to engage a corresponding mechanism on the corresponding connector. The latch <b>130</b> secures the connector <b>100</b> to the corresponding connector. In an alternative embodiment, the connector <b>100</b> and the corresponding connector may include any suitable corresponding engagement mechanisms to join the connector <b>100</b> to the corresponding connector.

0031<figref idref="DRAWINGS">FIG. 2</figref> illustrates the electrical connector <b>100</b> having the shield <b>114</b> removed. The housing <b>112</b> includes sidewalls <b>115</b> extending from the wire end <b>118</b> of the housing <b>112</b>. The wire end <b>118</b> of the housing <b>112</b> includes a cavity <b>113</b> defined by the sidewalls <b>115</b>. The cavity <b>113</b> includes a bottom surface <b>117</b>. A retention housing <b>138</b> is positioned within the cavity <b>113</b>. The retention housing <b>138</b> extends between the sidewalls <b>115</b> of the housing <b>112</b>. The retention housing <b>138</b> includes a top <b>140</b> and a bottom <b>142</b>. The bottom <b>142</b> of the retention housing <b>138</b> rests on the bottom surface <b>117</b> of the cavity <b>113</b>. The retention housing <b>138</b> extends from the bottom surface <b>117</b> of the cavity <b>113</b> to the top <b>124</b> of the housing <b>112</b>. The top <b>140</b> of the retention housing <b>138</b> is substantially flush with the top <b>124</b> of the housing <b>112</b>. Alternatively, the top <b>140</b> of the retention housing <b>138</b> may be recessed with respect to the top <b>124</b> of the housing <b>112</b> or extend beyond the top <b>124</b> of the housing <b>112</b>. The retention housing <b>138</b> is configured to retain the electrical components within the housing <b>112</b>.

0032<figref idref="DRAWINGS">FIG. 3</figref> illustrates the connector <b>100</b> with the retention housing <b>138</b> removed. The wire end <b>118</b> of the housing <b>112</b> includes a wire contact area <b>136</b> extending along the bottom surface <b>117</b> of the cavity <b>113</b>. The wire contact area <b>136</b> is configured to be covered by the retention housing <b>138</b> when the retention housing <b>138</b> is positioned in the housing <b>112</b>. The wire contact area <b>136</b> includes a front mounting surface <b>150</b> and a rear mounting surface <b>152</b>. The front mounting surface <b>150</b> is positioned closer to the wire end <b>118</b> of the housing <b>112</b> than the rear mounting surface <b>152</b>. The front mounting surface <b>150</b> is positioned proximate to the wire end <b>118</b> of the housing <b>112</b>. The rear mounting surface <b>152</b> is positioned between the front mounting surface <b>150</b> and the mating end <b>116</b> of the housing <b>112</b>. The front mounting surface <b>150</b> is positioned proximate to the bottom <b>126</b> of the housing <b>112</b>. The rear mounting surface <b>152</b> is stepped up vertically a distance D₂from the front mounting surface <b>150</b>. The rear mounting surface <b>152</b> is positioned between the front mounting surface <b>150</b> and the top <b>124</b> of the housing <b>112</b>. The rear mounting surface <b>152</b> and the front mounting surface <b>150</b> are offset to provide a predetermined tuning for the connector <b>100</b>. In an alternative embodiment, each of the front mounting surface <b>150</b> and the rear mounting surface <b>152</b> may be aligned within the same plane.

0033The wire contact area <b>136</b> is configured with a plurality of wire contacts <b>156</b>. The wire contacts <b>156</b> are configured as blades. The wire contacts <b>156</b> may be formed from phos-bronze and/or include a matte-tin over nickel plating. Optionally, the wire contacts <b>156</b> may be formed from any suitable conductive material. Front wire contacts <b>158</b> are positioned in the front mounting surface <b>150</b> and rear wire contacts <b>160</b> are positioned in the rear mounting surface <b>152</b>. The front wire contacts <b>158</b> are positioned closer to the bottom <b>126</b> of the housing than the rear wire contacts <b>160</b>. The rear wire contacts <b>160</b> are stepped up a distance <b>127</b> from the front wire contacts <b>158</b>. The front wire contacts <b>158</b> are positioned closer to the wire end <b>118</b> of the housing <b>112</b> than the rear wire contacts <b>160</b>.

0034The front wire contacts <b>158</b> extend in a plane <b>159</b>. The plane <b>159</b> is oriented non-orthogonally with respect to the wire end <b>118</b> of the housing <b>112</b>. The plane <b>159</b> is oriented non-orthogonally with respect to the loading direction <b>107</b> of the cable <b>106</b>. The front wire contacts <b>158</b> are arranged at an angle α with respect to the wire end <b>118</b> of the housing <b>112</b>. In one embodiment, the angle α may be 45 degrees.

0035The rear wire contacts <b>160</b> extend in a plane <b>161</b>. The plane <b>161</b> is oriented non-orthogonally with respect to the wire end <b>118</b> of the housing <b>112</b>. The plane <b>161</b> is oriented non-orthogonally with respect to the loading direction <b>107</b> of the cable <b>106</b>. The plane <b>161</b> is oriented non-parallel with respect to the plane <b>159</b> of the front wire contacts <b>158</b>. The rear wire contacts <b>160</b> are arranged at an angle β with respect to the wire end <b>118</b> of the housing <b>112</b>. In one embodiment, the angle β may be 45 degrees. The angle α is opposite the angle β. In an exemplary embodiment, the front wire contacts <b>158</b> are arranged 90 degrees with respect to the rear wire contacts <b>160</b>. In another embodiment, the front wire contacts <b>158</b> and the rear wire contacts <b>160</b> may be arranged at any angle with respect to one another. Optionally, the front wire contacts <b>158</b> may each be arranged at different angles α and the rear wire contacts <b>160</b> may each be arranged at different angles β. The angles α and β are configured to provide predetermined tuning for the connector <b>100</b>.

0036The wire contacts <b>156</b> include a slot <b>166</b>. The slot <b>166</b> is configured to receive a wire <b>110</b> (shown in <figref idref="DRAWINGS">FIG. 1</figref>) of the cable <b>106</b> (shown in <figref idref="DRAWINGS">FIG. 1</figref>). The slot <b>166</b> may be configured to receive a stranded and/or solid wire. In one embodiment, the wire contacts <b>156</b> may include any number of slots <b>166</b> to receive any number of wires <b>110</b>. The wire <b>110</b> is retained within the slot <b>166</b> through an interference fit. Optionally, the wire <b>110</b> may be soldered to the wire contact <b>156</b> after the wire <b>110</b> is inserted into the slot <b>166</b>. A first wire of a differential pair is configured to be joined to a front wire contact <b>158</b>. A second wire of the differential pair is configured to be joined to a rear wire contact <b>160</b>. The wires of the differential pairs of the cable <b>106</b> are separated between the front wire contacts <b>158</b> and the rear wire contacts <b>160</b>. Optionally, each wire <b>110</b> of a differential pair may be joined to front wire contacts <b>158</b> or rear wire contacts <b>160</b>.

0037The housing <b>112</b> includes a contact holder <b>170</b> positioned proximate to the mating end <b>116</b> of the housing <b>112</b>. The contact holder <b>170</b> includes partitions <b>172</b> and slots <b>174</b> formed between the partitions <b>172</b>. The mating contacts <b>128</b> are positioned within the slots <b>174</b>. The mating contacts <b>128</b> extend toward the top <b>124</b> of the housing <b>112</b>. The mating contacts <b>128</b> are electrically coupled to the wire contacts <b>156</b>. The mating contacts <b>128</b> include front mating contacts <b>180</b> and rear mating contacts <b>182</b>. The front mating contacts <b>180</b> are electrically joined to the front wire contacts <b>158</b>. The rear mating contacts <b>182</b> are electrically joined to the rear wire contacts <b>160</b>. The terms “front” and “rear” as used with respect to the mating contacts <b>128</b> designates the wire contact <b>156</b> to which the mating contact <b>128</b> is joined. The terms “front” and “rear” as used with respect to the mating contacts <b>128</b> are not used to designate a position of the mating contacts <b>128</b>. The mating contacts <b>128</b> are arranged in parallel. In another embodiment, the mating contacts <b>128</b> may be offset from one another. The front mating contacts <b>180</b> are positioned adjacent to and alternate with the rear mating contacts <b>182</b>. The front mating contacts <b>180</b> and the rear mating contacts <b>182</b> are alternated to achieve a predetermined tuning for the connector <b>100</b>. In another embodiment, the front mating contacts <b>180</b> and the rear mating contacts <b>182</b> may be arranged in any order that provides a predetermined performance of the connector.

0038<figref idref="DRAWINGS">FIG. 4</figref> illustrates an exploded view of the connector <b>100</b>. The connector <b>100</b> includes terminals <b>200</b>. The terminals <b>200</b> include an array of first terminals <b>202</b> and an array of second terminals <b>204</b>. The terminals <b>200</b> each include a wire end <b>206</b> and a mating end <b>208</b>. An arm <b>210</b> extends between the wire end <b>206</b> and the mating end <b>208</b>. A mating contact <b>128</b> is joined to the mating end <b>208</b> of each terminal <b>200</b>. A wire contact <b>156</b> is joined to the wire end <b>206</b> of each terminal <b>200</b>. The arm <b>210</b> of each terminal <b>200</b> extends between the mating contact <b>128</b> and the wire contact <b>156</b>. In an exemplary embodiment, the first terminals <b>202</b> include rear mating contacts <b>182</b> and rear wire contacts <b>160</b>. In an exemplary embodiment, the second terminals <b>204</b> include front mating contacts <b>180</b> and front wire contacts <b>158</b>.

0039The terminals <b>200</b> are configured to be positioned within the housing <b>112</b>. The housing <b>112</b> includes slots <b>212</b> that extend along the wire contact area <b>136</b> of the housing <b>112</b>. The slots <b>212</b> extend between the wire end <b>118</b> and the mating end <b>116</b> of the housing <b>112</b>. The slots <b>212</b> are aligned with and in communication with the slots <b>174</b> formed in the contact holder <b>170</b>. The first terminals <b>202</b> are positioned within the slots <b>212</b> such that the rear wire contacts <b>160</b> are positioned on the rear mounting surface <b>152</b>. The second terminals <b>204</b> are positioned within the slots <b>212</b> such that the front wire contacts <b>158</b> are positioned on the front mounting surface <b>150</b>. The front mating contacts <b>180</b> and the rear mating contacts <b>182</b> are configured to be positioned with the slots <b>174</b> of the contact holder <b>170</b>.

0040The retention housing <b>138</b> is configured to be positioned within the cavity <b>113</b> of the housing <b>112</b>. The retention housing <b>138</b> includes a front portion <b>220</b> and a rear portion <b>222</b>. The front portion <b>220</b> is configured to be positioned over the front mounting surface <b>150</b> of the housing <b>112</b>. The rear portion <b>222</b> is configured to be positioned over the rear mounting surface <b>152</b> of the housing <b>112</b>. The rear portion <b>222</b> is stepped up from the front portion <b>220</b> a distance <b>224</b>. The distance <b>224</b> corresponds to the distance D₂between the front mounting surface <b>150</b> and the rear mounting surface <b>152</b> so that the retention housing <b>138</b> rests on the wire contact area <b>136</b> of the housing <b>112</b>.

0041The retention housing <b>138</b> includes slots <b>226</b> extending therethrough. The slots <b>226</b> are configured to be positioned over the terminals <b>200</b> when the retention housing <b>138</b> is positioned within the housing <b>112</b>. The retention housing <b>138</b> holds the terminals <b>200</b> in position to provide stability to the terminals <b>200</b> within the housing <b>112</b>.

0042<figref idref="DRAWINGS">FIG. 5</figref> illustrates the housing <b>112</b>. The slots <b>212</b> extend between the wire end <b>118</b> and the mating end <b>116</b> of the housing <b>112</b>. The slots <b>212</b> include long slots <b>230</b> and short slots <b>232</b>. The short slots <b>232</b> extend from beneath the contact holder <b>170</b> along the rear mounting surface <b>152</b>. The short slots <b>232</b> are configured to receive and retain the first terminals <b>202</b>. The long slots <b>230</b> extend from beneath the contact holder <b>170</b> along the rear mounting surface <b>152</b> and the front mounting surface <b>150</b>. The long slots <b>230</b> are configured to receive and retain the second terminals <b>204</b>.

0043The short slots <b>232</b> include and arm portion <b>234</b> and a contact portion <b>236</b>. The arm portion <b>234</b> extends from beneath the contact holder <b>170</b> toward the wire end <b>118</b> of the housing <b>112</b>. The arm portion <b>234</b> extends substantially parallel to the sidewalls <b>115</b> of the housing <b>112</b>. Optionally, the arm portion <b>234</b> may extend at an angle with respect to the sidewalls <b>115</b> of the housing <b>112</b>. The contact portion <b>236</b> extends at an angle θ from the arm portion <b>234</b>. The contact portion <b>236</b> is oriented at an angle γ with respect to the wire end <b>118</b> of the housing <b>112</b>. The angle γ corresponds to the angle β of the rear wire contacts <b>160</b> with respect to the wire end <b>118</b> of the housing <b>112</b>. The arm portion <b>234</b> of the slot is configured to receive the arm <b>210</b> of the first terminal <b>202</b>. The contact portion <b>236</b> is configured to receive the rear wire contact <b>160</b> joined to the arm <b>210</b> of the first terminal <b>202</b>. The rear mating contact <b>182</b> that is joined to the arm <b>210</b> of the first terminal <b>202</b> is configured to be positioned within a section of the arm portion <b>234</b> that extends beneath the contact holder <b>170</b>. The rear mating contact <b>182</b> is retained with the contact holder <b>170</b>.

0044The long slots <b>230</b> include and arm portion <b>242</b> and a contact portion <b>244</b>. The arm portion <b>242</b> extends from beneath the contact holder <b>170</b> toward the wire end <b>118</b> of the housing <b>112</b>. The arm portion <b>242</b> extends substantially parallel to the sidewalls <b>115</b> of the housing <b>112</b>. Optionally, the arm portion <b>242</b> may extend at an angle with respect to the sidewalls <b>115</b> of the housing <b>112</b>. The contact portion <b>244</b> extends at an angle σ from the arm portion <b>242</b>. The contact portion <b>244</b> is oriented at an angle τ with respect to the wire end <b>118</b> of the housing <b>112</b>. The angle τ corresponds to the angle α of the front wire contacts <b>158</b> with respect to the wire end <b>118</b> of the housing <b>112</b>. The arm portion <b>242</b> of the slot is configured to receive the arm <b>210</b> of the second terminal <b>204</b>. The contact portion <b>244</b> is configured to receive the front wire contact <b>158</b> joined to the arm <b>210</b> of the second terminal <b>204</b>. The front mating contact <b>180</b> that is joined to the arm <b>210</b> of the second terminal <b>204</b> is configured to be positioned within a section of the arm portion <b>242</b> that extends beneath the contact holder <b>170</b>. The front mating contact <b>180</b> is retained with the contact holder <b>170</b>.

0045<figref idref="DRAWINGS">FIG. 6</figref> illustrates a first terminal <b>202</b>. The first terminal <b>202</b> includes a short wire end <b>250</b> and a short mating end <b>252</b>. A short arm <b>254</b> extends between the short wire end <b>250</b> and the short mating end <b>252</b>. The short arm <b>254</b> has a length L₁defined between the short wire end <b>250</b> and the short mating end <b>252</b>. A rear mating contact <b>182</b> is joined to the short mating end <b>252</b> of the first terminal <b>202</b>. The rear mating contact <b>182</b> includes a top <b>258</b> and a bottom <b>260</b>. The rear mating contact <b>182</b> has a height H₁defined between the top <b>258</b> and the bottom <b>260</b> of the rear mating contact <b>182</b>. The top <b>258</b> includes flanges <b>262</b> that are configured to mate with a contact of a corresponding connector. A rear wire contact <b>160</b> is joined to the short wire end <b>250</b> of the first terminal <b>202</b>. The rear wire contact <b>160</b> has a top <b>266</b> and a bottom <b>268</b>. The rear wire contact <b>160</b> has a height H₃defined between the top <b>266</b> and the bottom <b>268</b>.

0046<figref idref="DRAWINGS">FIG. 7</figref> illustrates a second terminal <b>204</b>. The second terminal <b>204</b> includes a long wire end <b>280</b> and a long mating end <b>282</b>. A long arm <b>284</b> extends between the long wire end <b>280</b> and the long mating end <b>282</b>. The long arm <b>284</b> has a length L₂defined between the long wire end <b>280</b> and the long mating end <b>282</b>. The length L₂of the long arm <b>284</b> is greater than the length L₁of the short arm <b>254</b> (shown in <figref idref="DRAWINGS">FIG. 6</figref>). The long mating <b>282</b> of the second terminal <b>204</b> is configured to be aligned with the short mating <b>252</b> of the first terminal <b>202</b> when the second terminal <b>204</b> and the first terminal <b>202</b> are inserted in to the housing <b>112</b>. The long wire end <b>280</b> of the second terminal <b>204</b> is configured to be positioned closer to the wire end <b>102</b> of the housing <b>112</b> than the short wire end <b>250</b> of the first terminal <b>202</b> when the second terminal <b>204</b> and the first terminal <b>202</b> are inserted into the housing <b>112</b>.

0047A front mating contact <b>180</b> in joined to the long mating end <b>282</b> of the second terminal <b>204</b>. The front mating contact <b>180</b> has a top <b>288</b> and a bottom <b>290</b>. The front mating contact <b>180</b> has a height H₄defined between the top <b>288</b> and the bottom <b>290</b>. The height H₄of the front mating contact <b>180</b> is greater than the height H₁of the rear mating contact <b>182</b> (shown in <figref idref="DRAWINGS">FIG. 6</figref>). Optionally, the height H₄of the front mating contact <b>180</b> may be the same or less than the height H₁of the rear mating contact <b>182</b>. The front mating contact <b>180</b> includes flanges <b>294</b> that are configured to mates with a contact of a corresponding connector.

0048A front wire contact <b>158</b> is joined to the long wire end <b>280</b> of the second terminal <b>204</b>. The front wire contact <b>158</b> has a top <b>296</b> and a bottom <b>298</b>. The front wire contact <b>158</b> has a height H₂defined between the top <b>296</b> and the bottom <b>298</b>. The height H₂of the front wire contact <b>158</b> is equal to the height H₃of the rear wire contact <b>160</b> (shown in <figref idref="DRAWINGS">FIG. 6</figref>). Optionally, the height H₂of the front wire contact <b>158</b> may be less than or greater than the height H₃of the rear wire contact <b>160</b>.

0049<figref idref="DRAWINGS">FIG. 8</figref> illustrates a terminal array <b>310</b> formed in accordance with an embodiment. The terminal array <b>310</b> includes second terminals <b>204</b> and first terminals <b>202</b>. The long mating end <b>282</b> of the second terminal <b>204</b> is aligned with the short mating end <b>252</b> of the first terminal <b>202</b>. The long wire end <b>280</b> of the second terminal <b>204</b> is offset from the short wire end <b>250</b> of the first terminal <b>202</b>. The terminal array <b>310</b> includes a bottom <b>312</b> defined by a bottom <b>314</b> of the second terminals <b>204</b>. The terminal array <b>310</b> includes a top <b>316</b> defined by a top <b>318</b> of the mating contacts <b>128</b>. The terminal array <b>310</b> has a height H₅defined between the top <b>316</b> and the bottom <b>312</b>. The terminal array <b>310</b> has a length L₃defined between a long mating end <b>282</b> of the second terminal <b>204</b> and an end <b>324</b> of the front wire contact <b>158</b>.

0050The second terminal <b>204</b> and the first terminal <b>202</b> are offset with respect to the height H₅of the terminal array <b>310</b>. The rear wire contact <b>160</b> and the front wire contact <b>158</b> are offset with respect to the height H₅of the terminal array <b>310</b>. The rear wire contact <b>160</b> and the front wire contact <b>158</b> are offset with respect to the length L₃of the terminal array <b>310</b>. The mating contacts <b>128</b> are aligned within the terminal array <b>310</b>. Optionally, the mating contacts <b>128</b> may be offset with respect to the length L₃of the terminal array <b>310</b>.

0051<figref idref="DRAWINGS">FIG. 9</figref> illustrates an electrical connector <b>400</b> formed in accordance with another embodiment. The connector <b>400</b> includes a housing <b>402</b> having a mating end <b>404</b> and a wire end <b>406</b>. The housing <b>402</b> includes a bottom <b>405</b> extending between the mating end <b>404</b> and the wire end <b>406</b>. A contact holder <b>408</b> is positioned proximate to the mating end <b>404</b> of the housing <b>402</b>. The contact holder <b>408</b> includes slots <b>409</b> separated by partitions <b>411</b>. A cavity <b>410</b> is positioned proximate to the wire end <b>406</b> of the housing <b>402</b>. The cavity <b>410</b> is defined by sidewalls <b>412</b> of the housing <b>402</b>. A terminal tray <b>414</b> is configured to be positioned within the cavity <b>410</b> of the housing <b>402</b>. The terminal tray <b>414</b> is configured to receive terminals <b>416</b>.

0052The terminals <b>416</b> include an array of first terminals <b>418</b> and an array of second terminals <b>420</b>. The terminals <b>416</b> each include a wire end <b>422</b> and a mating end <b>424</b>. An arm <b>426</b> extends between the wire end <b>422</b> and the mating end <b>424</b>. An aperture <b>428</b> is formed at the mating end <b>424</b> of each terminal <b>416</b>. A wire contact <b>430</b> is joined to the wire end <b>422</b> of each terminal <b>416</b>. The arm <b>426</b> of each terminal <b>416</b> extends between the aperture <b>428</b> and the wire contact <b>430</b>. In an exemplary embodiment, the first terminals <b>148</b> include rear wire contacts <b>432</b> and the second terminals <b>420</b> include front wire contacts <b>434</b>.

0053The terminals <b>416</b> are configured to be positioned within the terminal tray <b>414</b>. The terminal tray <b>414</b> includes slots <b>436</b> that extend along the terminal tray <b>414</b>. The slots <b>436</b> extend between a wire end <b>438</b> and a mating end <b>440</b> of the terminal tray <b>414</b>. The slots <b>436</b> are aligned with and in communication with the slots <b>409</b> formed in the contact holder <b>408</b>. The first terminals <b>418</b> are positioned within the slots <b>436</b> such that the rear wire contacts <b>432</b> are positioned on a rear mounting surface <b>442</b> of the terminal tray <b>414</b>. The second terminals <b>420</b> are positioned within the slots <b>436</b> such that the front wire contacts <b>434</b> are positioned on a front mounting surface <b>444</b> of the terminal tray <b>414</b>.

0054Mating contacts <b>446</b> are configured to be inserted into the slots <b>409</b> of the contact holder <b>408</b>. The mating contacts <b>446</b> include connectors <b>448</b> that are received in the apertures <b>428</b> of the terminals <b>416</b>. The connectors <b>448</b> are configured to be retained within the apertures <b>428</b> through an interference fit. For example, the connectors <b>448</b> may be eye-of-the-needle connectors that are press-fit into the apertures <b>428</b>. In one embodiment, the mating contacts <b>446</b> may be soldered, welded, or otherwise adhered to the terminals <b>416</b>. The mating contacts <b>446</b> include front mating contacts <b>450</b> and rear mating contacts <b>452</b>. The front mating contacts <b>450</b> are joined to the second terminals <b>420</b>. The rear mating contacts <b>452</b> are joined to the first terminals <b>418</b>.

0055A retention housing <b>454</b> is configured to be positioned within the cavity <b>410</b> of the housing <b>402</b>. The retention housing <b>454</b> includes a front portion <b>456</b> and a rear portion <b>458</b>. The front portion <b>456</b> is configured to be positioned over the front mounting surface <b>444</b> of the terminal tray <b>414</b>. The rear portion <b>222</b> is configured to be positioned over the rear mounting surface <b>442</b> of the terminal tray <b>414</b>. The retention housing <b>454</b> includes slots <b>460</b> extending therethrough. The slots <b>460</b> are configured to be positioned over the terminals <b>416</b> when the retention housing <b>454</b> is positioned within the housing <b>402</b>. The retention housing <b>454</b> holds the terminals <b>416</b> in position to provide stability to the terminals <b>416</b> within the terminal tray <b>414</b>.

0056<figref idref="DRAWINGS">FIG. 10</figref> illustrates an electrical assembly <b>470</b> formed in accordance with an embodiment. The electrical assembly <b>470</b> includes the terminal tray <b>414</b> and the terminals <b>416</b>. The front mounting surface <b>444</b> of the terminal tray <b>414</b> is positioned closer to the wire end <b>438</b> of the terminal tray <b>414</b> than the rear mounting surface <b>442</b> of the terminal tray <b>414</b>. The terminal tray <b>414</b> is configured to position within the housing <b>402</b> (shown in <figref idref="DRAWINGS">FIG. 9</figref>) such that the front mounting surface <b>444</b> is positioned proximate to the bottom <b>405</b> (shown in <figref idref="DRAWINGS">FIG. 9</figref>) of the housing <b>402</b> than the rear mounting surface <b>442</b>. The rear mounting surface <b>442</b> is stepped up vertically a distance D₁from the front mounting surface <b>444</b>. The rear mounting surface <b>442</b> and the front mounting surface <b>444</b> are offset to provide a predetermined tuning for the connector <b>400</b>. In an alternative embodiment, each of the front mounting surface <b>444</b> and the rear mounting surface <b>442</b> may be aligned within the same plane.

0057The front wire contacts <b>434</b> are positioned in the front mounting surface <b>444</b> and rear wire contacts <b>432</b> are positioned in the rear mounting surface <b>442</b>. The front wire contacts <b>434</b> are configured to be positioned closer to the bottom <b>405</b> of the housing <b>402</b> than the rear wire contacts <b>432</b>. The front wire contacts <b>434</b> are configured to be positioned closer to the wire end <b>438</b> of the terminal tray <b>414</b> than the rear wire contacts <b>432</b>.

0058The front wire contacts <b>434</b> are arranged at an angle χ with respect to the wire end <b>438</b> of the terminal tray <b>414</b>. In one embodiment, the angle χ may be 45 degrees. The rear wire contacts <b>432</b> are arranged at an angle υ with respect to the wire end <b>438</b> of the terminal tray <b>414</b>. In one embodiment, the angle υ may be 45 degrees. The angle χ is opposite the angle υ. In an exemplary embodiment, the front wire contacts <b>434</b> are arranged 90 degrees with respect to the rear wire contacts <b>432</b>. In another embodiment, the front wire contacts <b>434</b> and the rear wire contacts <b>432</b> may be arranged at any angle with respect to one another. Optionally, the front wire contacts <b>434</b> may each be arranged at different angles χ and the rear wire contacts <b>432</b> may each be arranged at different angles υ. The angles χ and υ are configured to provide predetermined tuning for the connector <b>400</b>.

0059The mating contacts <b>446</b> are electrically coupled to the terminals <b>416</b>. The mating contacts <b>446</b> include front mating contacts <b>484</b> and rear mating contacts <b>486</b>. The front mating contacts <b>484</b> are electrically joined to the second terminals <b>420</b>. The rear mating contacts <b>486</b> are electrically joined to the first terminals <b>418</b>. The mating contacts <b>446</b> are arranged in parallel. In another embodiment, the mating contacts <b>446</b> may be offset from one another. The front mating contacts <b>484</b> are positioned adjacent to and alternate with the rear mating contacts <b>486</b>. The front mating contacts <b>484</b> and the rear mating contacts <b>486</b> are alternated to achieve a predetermined tuning for the connector <b>400</b>. In another embodiment, the front mating contacts <b>484</b> and the rear mating contacts <b>486</b> may be arranged in any order that provides a predetermined performance of the connector.

0060<figref idref="DRAWINGS">FIG. 11</figref> illustrates a first terminal <b>418</b>. The first terminal <b>418</b> includes a short wire end <b>490</b> and a short mating end <b>492</b>. A short arm <b>494</b> extends between the short wire end <b>490</b> and the short mating end <b>492</b>. The short arm <b>494</b> has a length L₄defined between the short wire end <b>490</b> and the short mating end <b>492</b>. A ring <b>498</b> is joined to the short mating end <b>492</b> of the first terminal <b>418</b>. The ring <b>498</b> has an aperture <b>499</b> extending therethrough. The aperture <b>499</b> is configured to receive a rear mating contact <b>486</b>. A rear wire contact <b>432</b> is joined to the short wire end <b>490</b> of the first terminal <b>418</b>. The rear wire contact <b>432</b> has a top <b>500</b> and a bottom <b>502</b>. The rear wire contact <b>432</b> has a height <b>504</b> defined between the top <b>500</b> and the bottom <b>502</b>.

0061<figref idref="DRAWINGS">FIG. 12</figref> illustrates a second terminal <b>420</b>. The second terminal <b>420</b> includes a long wire end <b>506</b> and a long mating end <b>508</b>. A long arm <b>510</b> extends between the long wire end <b>506</b> and the long mating end <b>508</b>. The long arm <b>510</b> has a length L₅defined between the long wire end <b>506</b> and the long mating end <b>508</b>. The length L₅of the long arm <b>510</b> is greater than the length L₄of the short arm <b>494</b> (shown in <figref idref="DRAWINGS">FIG. 11</figref>). A ring <b>514</b> in joined to the long mating end <b>508</b> of the second terminal <b>420</b>. The ring <b>514</b> has an aperture <b>516</b> extending therethrough. The aperture <b>516</b> is configured to receive a front mating contact <b>484</b>.

0062A front wire contact <b>434</b> is joined to the long wire end <b>506</b> of the second terminal <b>420</b>. The front wire contact <b>434</b> has a top <b>518</b> and a bottom <b>520</b>. The front wire contact <b>434</b> has a height <b>522</b> defined between the top <b>518</b> and the bottom <b>520</b>. The height <b>522</b> of the front wire contact <b>434</b> is equal to the height <b>504</b> of the rear wire contact <b>432</b> (shown in <figref idref="DRAWINGS">FIG. 11</figref>). Optionally, the height <b>522</b> of the front wire contact <b>434</b> may be less than or greater than the height <b>504</b> of the rear wire contact <b>432</b>.

0063<figref idref="DRAWINGS">FIG. 13</figref> illustrates a rear mating contact <b>486</b>. The rear mating contact <b>486</b> is configured to be joined to the short mating end <b>492</b> of the first terminal <b>418</b>. The rear mating contact <b>486</b> includes a top <b>530</b> and a bottom <b>532</b>. The rear mating contact <b>486</b> has a height H₆defined between the top <b>530</b> and the bottom <b>532</b> of the rear mating contact <b>486</b>. The bottom <b>532</b> of the rear mating contact <b>486</b> has a rear connector <b>536</b> extending therefrom. The rear connector <b>536</b> is configured as an eye-of-the-needle connector. The rear connector <b>536</b> is configured to be press-fit into the aperture <b>499</b> of the first terminal <b>418</b>.

0064<figref idref="DRAWINGS">FIG. 14</figref> illustrates a front mating contact <b>484</b>. The front mating contact <b>484</b> is configured to be joined to the long mating end <b>508</b> of the second terminal <b>420</b>. The front mating contact <b>484</b> has a top <b>540</b> and a bottom <b>542</b>. The front mating contact <b>484</b> has a height H₇defined between the top <b>540</b> and the bottom <b>542</b>. The height H₇of the front mating contact <b>484</b> is greater than the height H₆of the rear mating contact <b>486</b> (shown in <figref idref="DRAWINGS">FIG. 13</figref>). Optionally, the height H₇of the front mating contact <b>484</b> may be the same or less than the height H₆of the rear mating contact <b>486</b>. The bottom <b>542</b> of the front mating contact <b>484</b> has a front connector <b>546</b> extending therefrom. The front connector <b>546</b> is configured as an eye-of-the-needle connector. The front connector <b>546</b> is configured to be press-fit into the aperture <b>516</b> of the second terminal <b>420</b>.

0065<figref idref="DRAWINGS">FIG. 15</figref> illustrates a terminal array <b>600</b> formed in accordance with another embodiment. The terminal array <b>600</b> includes the second terminals <b>420</b> and first terminals <b>418</b>. The terminal array <b>600</b> includes a bottom <b>602</b> defined by a bottom <b>604</b> of the second terminal <b>420</b>. The terminal array <b>600</b> includes a top <b>606</b> defined by the tops <b>530</b>, <b>540</b> of the mating contacts <b>446</b>. The terminal array <b>600</b> has a height H₈defined between the top <b>608</b> and the bottom <b>602</b>. The terminal array <b>600</b> has a length L₆defined between a long mating end <b>508</b> of the second terminal <b>420</b> and an end <b>614</b> of the front wire contact <b>434</b>.

0066The second terminal <b>420</b> and the first terminal <b>418</b> are offset with respect to the height H₈of the terminal array <b>600</b>. The rear wire contact <b>432</b> and the front wire contact <b>434</b> are offset with respect to the height H₈of the terminal array <b>600</b>. The rear wire contact <b>432</b> and the front wire contact <b>434</b> are offset with respect to the length L₆of the terminal array <b>600</b>. The mating contacts <b>446</b> are aligned within the terminal array <b>600</b>. Optionally, the mating contacts <b>446</b> may be offset with respect to the length L₆of the terminal array <b>600</b>.

0067It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the various embodiments of the invention without departing from their scope. While the dimensions and types of materials described herein are intended to define the parameters of the various embodiments of the invention, the embodiments are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the various embodiments of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.

0068This written description uses examples to disclose the various embodiments of the invention, including the best mode, and also to enable any person skilled in the art to practice the various embodiments of the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the various embodiments of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if the examples have structural elements that do not differ from the literal language of the claims, or if the examples include equivalent structural elements with insubstantial differences from the literal languages of the claims.